U.S. patent application number 14/808227 was filed with the patent office on 2017-01-26 for shaft-based surgical forceps and method of manufacturing the same.
The applicant listed for this patent is COVIDIEN LP. Invention is credited to Purvish SONI.
Application Number | 20170020543 14/808227 |
Document ID | / |
Family ID | 56507521 |
Filed Date | 2017-01-26 |
United States Patent
Application |
20170020543 |
Kind Code |
A1 |
SONI; Purvish |
January 26, 2017 |
SHAFT-BASED SURGICAL FORCEPS AND METHOD OF MANUFACTURING THE
SAME
Abstract
A surgical instrument includes a shaft defining a proximal end,
a distal end, an interior surface, and an exterior surface. The
shaft includes a pair of channels defined in the interior surface
thereof towards the distal end of the shaft. A drive member is
movably disposed within the shaft. An end effector assembly is
pivotably coupled to the shaft towards the distal end of the shaft.
A cam pin operably couples the end effector assembly and the drive
member such that movement of the drive member relative to the shaft
manipulates the end effector assembly. Ends of the cam pin extend
outwardly from the end effector assembly and are received within
the channels of the shaft to guide movement of the cam pin relative
to the shaft in response to movement of the drive member relative
to the shaft.
Inventors: |
SONI; Purvish; (Denver,
CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
COVIDIEN LP |
Mansfield |
MA |
US |
|
|
Family ID: |
56507521 |
Appl. No.: |
14/808227 |
Filed: |
July 24, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61B 2017/00084
20130101; A61B 2018/1455 20130101; A61B 2017/00026 20130101; A61B
2017/00477 20130101; A61B 34/35 20160201; A61B 34/77 20160201; A61B
2017/00734 20130101; A61B 17/29 20130101; A61B 2017/2936 20130101;
A61B 34/76 20160201; A61B 2017/00526 20130101; A61B 2017/2902
20130101; A61B 2018/00589 20130101 |
International
Class: |
A61B 17/29 20060101
A61B017/29; A61B 17/28 20060101 A61B017/28; A61B 18/14 20060101
A61B018/14 |
Claims
1. A surgical instrument, comprising: a shaft defining a proximal
end, a distal end, an interior surface, and an exterior surface,
the shaft including a pair of channels defined in the interior
surface thereof towards the distal end of the shaft; a drive member
movably disposed within the shaft; an end effector assembly
pivotably coupled to the shaft towards the distal end of the shaft;
and a cam pin operably coupling the end effector assembly and the
drive member such that movement of the drive member relative to the
shaft manipulates the end effector assembly, wherein ends of the
cam pin extend outwardly from the end effector assembly and are
received within the channels of the shaft to guide movement of the
cam pin relative to the shaft in response to movement of the drive
member relative to the shaft.
2. The surgical instrument according to claim 1, wherein the
channels are formed via embossed features raised in relief from the
exterior surface of the shaft.
3. The surgical instrument according to claim 1, wherein each
channel defines an angled section and a longitudinal section, and
wherein the ends of the cam pin are moved through the longitudinal
sections of the channels in response to movement of the drive
member relative to the shaft.
4. The surgical instrument according to claim 3, wherein the ends
of the cam pin are configured for insertion into the angled
sections of the channels and translation therealong to the
longitudinal sections of the channels.
5. The surgical instrument according to claim 1, wherein the end
effector assembly includes first and second jaw members each
defining at least one cam slot, the cam pin configured for
insertion through the least one cam slot of each of the first and
second jaw members and translation therealong to move the first and
second jaw members between a spaced-apart position and an
approximated position in response to movement of the drive member
relative to the shaft.
6. The surgical instrument according to claim 5, wherein the first
and second jaw members each define at least one pivot aperture and
wherein a pivot pin extends through the at least one pivot aperture
of each of the first and second jaw members to pivotably couple the
first and second jaw members to one another.
7. The surgical instrument according to claim 6, further including
a clevis extending distally from the distal end of the shaft, the
clevis including a pair of spaced-apart clevis members each
defining an aperture, wherein the pivot pin is further configured
to extend through the apertures of the clevis members to pivotably
couple the first and second jaw members to the shaft.
8. The surgical instrument according to claim 5, wherein the drive
member defines an aperture towards a distal end thereof, the
aperture of the drive member configured to receive the cam pin such
that movement of the drive member relative to the shaft
correspondingly moves the cam pin relative to the shaft.
9. The surgical instrument according to claim 5, wherein each of
the first and second jaw members includes at least one proximal
flange and a distal body, the at least one proximal flange defining
the at least one cam slot therethrough.
10. The surgical instrument according to claim 9, wherein the
distal body of each of the first and second jaw members include an
electrically-conductive plate, the electrically-conductive plates
configured to grasp tissue therebetween in the approximated
position of the first and second jaw members and adapted to connect
to a source of energy for treating tissue grasped therebetween.
11. The surgical instrument according to claim 1, further
including: a housing engaging the proximal end of the shaft; a
drive assembly disposed within the housing and operably coupled to
the drive member; and a handle assembly operably coupled to the
housing and the drive assembly, the handle assembly including a
movable handle movable between a first position and a second
position relative to the housing to move the drive member relative
to the shaft.
12. A method of manufacturing a surgical instrument, comprising:
coupling a cam pin with an end effector assembly and a drive member
to operably couple the end effector assembly and the drive assembly
to one another, such that ends of the cam pin extend outwardly from
the end effector assembly; and sliding the ends of the cam pin into
channels defined within a shaft towards a distal end of the shaft
to operably couple the end effector assembly and the drive member
with the shaft, wherein the channels retain the cam pin coupled to
the end effector assembly and the drive member.
13. The method according to claim 12, wherein the end effector
assembly includes first and second jaw members and wherein the
method further includes inserting a pivot pin through the first and
second jaw members to pivotably couple the first and second jaw
members to one another.
14. The method according to claim 13, wherein the first and second
jaw members are pivotably coupled to one another prior to sliding
the ends of the cam pin into the channels, and wherein the method
further includes pivotably coupling ends of the pivot pin to the
shaft.
15. The method according to claim 13, wherein the method further
includes, after sliding the ends of the cam pin into the channels,
inserting the pivot pin through apertures defined within the shaft
and the first and second jaw members to pivotably couple the first
and second jaw members to one another and the shaft.
16. The method according to claim 12, wherein sliding the ends of
the cam pin into the channels includes inserting the ends of the
cam pin into angled sections of the channels, sliding the ends of
the cam pin through the angled sections of the channels, and
sliding the ends of the cam pin into longitudinal sections of the
channels.
17. The method according to claim 12, further including coupling
the drive member to a drive assembly, wherein coupling the drive
member to the drive assembly retains the ends of the cam pin with
the longitudinal sections of the channels.
18. A method of manufacturing a surgical instrument, comprising:
inserting a cam pin through cam slots defined within first and
second jaw members to operably couple the first and second jaw
members to one another, such that ends of the cam pin extend
outwardly from the first and second jaw members; inserting the ends
of the cam pin into angled sections of channels defined within a
shaft; sliding the ends of the cam pin through the angled sections
of the channels and into longitudinal sections of the channels; and
inserting a pivot pin through apertures defined within the first
and second jaw members and apertures defined within the shaft to
pivotably couple the first and second jaw members to one another
and the shaft.
19. The method according to claim 18, further including inserting
the cam pin through an aperture defined within a drive member to
operably couple the first and second jaw members to the drive
member.
20. The method according to claim 12, wherein inserting the pivot
pin through apertures defined within the first and second jaw
members is performed before inserting the cam pin and wherein
inserting the pivot pin through the apertures defined within the
shaft is performed after inserting the cam pin.
Description
BACKGROUND
[0001] Technical Field
[0002] The present disclosure relates to surgical instruments and,
more particularly, to shaft-based surgical forceps and methods of
manufacturing shaft-based surgical forceps.
[0003] Background of Related Art
[0004] A forceps or hemostat is a plier-like instrument which
relies on mechanical action between its jaws to grasp, clamp, and
constrict tissue. Energy-based forceps utilize both mechanical
clamping action and energy, e.g., electrosurgical energy,
ultrasonic energy, light energy, microwave energy, heat, etc., to
affect hemostasis by heating tissue to treat, e.g., coagulate,
cauterize, and/or seal, tissue.
[0005] Shaft-based forceps typically employ a shaft having a handle
at a proximal end thereof and a pair of jaw members at a distal end
thereof. A drive assembly extending through the shaft operably
couples the handle with the jaw members such that actuation of the
handle moves one or both of the jaw members relative to the other
to grasp tissue therebetween.
[0006] As the dimensions of shaft-based forceps are minimized, the
sizes of the components disposed therein are also minimized,
requiring that these components be capable of withstanding greater
tolerances. Thus, there is presented a design challenge of
providing a suitably small shaft-based forceps while reducing the
tolerances of the components disposed therein to acceptable
levels.
SUMMARY
[0007] As used herein, the term "distal" refers to the portion that
is being described which is further from a user, while the term
"proximal" refers to the portion that is being described which is
closer to a user. Further, to the extent consistent, any of the
aspects described herein may be used in conjunction with any or all
of the other aspects described herein.
[0008] A surgical instrument provided in accordance with aspects of
the present disclosure includes a shaft defining a proximal end, a
distal end, an interior surface, and an exterior surface. The shaft
includes a pair of channels defined in the interior surface thereof
towards the distal end of the shaft. A drive member is movably
disposed within the shaft and an end effector assembly is pivotably
coupled to the shaft towards the distal end of the shaft. A cam pin
operably couples the end effector assembly and the drive member
such that movement of the drive member relative to the shaft
manipulates the end effector assembly. Ends of the cam pin extend
outwardly from the end effector assembly and are received within
the channels of the shaft to guide movement of the cam pin relative
to the shaft in response to movement of the drive member relative
to the shaft.
[0009] In an aspect of the present disclosure, the channels of the
shaft are formed via embossed features raised in relief from the
exterior surface of the shaft.
[0010] In another aspect of the present disclosure, each channel
defines an angled section and a longitudinal section. The ends of
the cam pin are moved through the longitudinal sections of the
channels in response to movement of the drive member relative to
the shaft. The angled sections of the channels may be used to
facilitate assembly, as detailed below.
[0011] In yet another aspect of the present disclosure, the ends of
the cam pin are configured for insertion into the angled sections
of the channels and translation therealong to the longitudinal
sections of the channels.
[0012] In still another aspect of the present disclosure, the end
effector assembly includes first and second jaw members each
defining at least one cam slot. The cam pin is configured for
insertion through the least one cam slot of each of the first and
second jaw members and translation therealong to move the first and
second jaw members between a spaced-apart position and an
approximated position in response to movement of the drive member
relative to the shaft.
[0013] In still yet another aspect of the present disclosure, the
first and second jaw members each define at least one pivot
aperture. A pivot pin extends through the at least one pivot
aperture of each of the first and second jaw members to pivotably
couple the first and second jaw members to one another.
[0014] In another aspect of the present disclosure, a clevis
extends distally from the distal end of the shaft and includes a
pair of spaced-apart clevis members. Each clevis member defines an
aperture. The pivot pin is further configured to extend through the
apertures of the clevis members to pivotably couple the first and
second jaw members to the shaft.
[0015] In still another aspect of the present disclosure, the drive
member defines an aperture towards a distal end thereof. The
aperture of the drive member is configured to receive the cam pin
such that movement of the drive member relative to the shaft
correspondingly moves the cam pin relative to the shaft.
[0016] In yet another aspect of the present disclosure, each of the
first and second jaw members includes at least one proximal flange
and a distal body. The at least one proximal flange of each of the
jaw members defines the corresponding at least one cam slot
therethrough.
[0017] In another aspect of the present disclosure, the distal body
of each of the first and second jaw members include an
electrically-conductive plate. The electrically-conductive plates
are configured to grasp tissue therebetween in the approximated
position of the first and second jaw members and adapted to connect
to a source of energy for treating tissue grasped therebetween.
[0018] In still yet another aspect of the present disclosure, the
instrument further includes a housing engaging the proximal end of
the shaft, a drive assembly disposed within the housing and
operably coupled to the drive member, and a handle assembly
operably coupled to the housing and the drive assembly. The handle
assembly includes a movable handle movable between a first position
and a second position relative to the housing to move the drive
member relative to the shaft.
[0019] A method of manufacturing a surgical instrument provided in
accordance with aspects of the present disclosure includes coupling
a cam pin with an end effector assembly and a drive member to
operably couple the end effector assembly and the drive assembly to
one another. The cam pin is positioned such that ends of the cam
pin extend outwardly from the end effector assembly. The method
further includes sliding the ends of the cam pin into channels
defined within a shaft towards a distal end of the shaft to
operably couple the end effector assembly and the drive member with
the shaft. The channels retain the cam pin coupled to the end
effector assembly and the drive member.
[0020] In an aspect of the present disclosure, the end effector
assembly includes first and second jaw members and the method
further includes inserting a pivot pin through the first and second
jaw members to pivotably couple the first and second jaw members to
one another.
[0021] In another aspect of the present disclosure, the first and
second jaw members are pivotably coupled to one another prior to
sliding the ends of the cam pin into the channels. In such aspects,
the method further includes pivotably coupling ends of the pivot
pin to the shaft.
[0022] In another aspect of the present disclosure, the method
further includes, after sliding the ends of the cam pin into the
channels, inserting the pivot pin through apertures defined within
the shaft and the first and second jaw members to pivotably couple
the first and second jaw members to one another and the shaft.
[0023] In yet another aspect of the present disclosure, sliding the
ends of the cam pin into the channels includes inserting the ends
of the cam pin into angled sections of the channels, sliding the
ends of the cam pin through the angled sections of the channels,
and sliding the ends of the cam pin into longitudinal sections of
the channels.
[0024] In still another aspect of the present disclosure, the
method further includes coupling the drive member to a drive
assembly. Coupling the drive member to the drive assembly retains
the ends of the cam pin with the longitudinal sections of the
channels.
[0025] Another method of manufacturing a surgical instrument
provided in accordance with aspects of the present disclosure
includes inserting a cam pin through cam slots defined within first
and second jaw members to operably couple the first and second jaw
members to one another, such that ends of the cam pin extend
outwardly from the first and second jaw members. The method further
includes inserting the ends of the cam pin into angled sections of
channels defined within a shaft, sliding the ends of the cam pin
through the angled sections of the channels and into longitudinal
sections of the channels, and inserting a pivot pin through
apertures defined within the first and second jaw members and
apertures defined within the shaft to pivotably couple the first
and second jaw members to one another and the shaft.
[0026] In an aspect of the present disclosure, the method further
includes inserting the cam pin through an aperture defined within a
drive member to operably couple the first and second jaw members to
the drive member.
[0027] In another aspect of the present disclosure, inserting the
pivot pin through apertures defined within the first and second jaw
members is performed before inserting the cam pin, and inserting
the pivot pin through the apertures defined within the shaft is
performed after inserting the cam pin.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Various aspects and features of the present disclosure
described herein with reference to the drawings wherein:
[0029] FIG. 1 is a perspective view of a shaft-based surgical
forceps provided in accordance with the present disclosure with jaw
members of the end effector assembly thereof disposed in a
spaced-apart position;
[0030] FIG. 2 is a rear, perspective view of the forceps of FIG. 1
with the jaw members disposed in the approximated position and a
portion of the housing removed to illustrate the internal
components thereof;
[0031] FIG. 3 is an enlarged, rear, perspective, exploded view of
the drive assembly, shaft, and end effector assembly of the forceps
of FIG. 1;
[0032] FIG. 4 is a side view of the distal end of the forceps of
FIG. 1 with the jaw members disposed in the spaced-apart
position;
[0033] FIG. 5 is a side view of the distal end of the forceps of
FIG. 1 with the jaw members disposed in the approximated position;
and
[0034] FIG. 6 is transverse, cross-sectional view of the distal end
of the forceps of FIG. 1 taken across section line "6-6" of FIG.
5.
DETAILED DESCRIPTION
[0035] Referring generally to FIGS. 1-3, a shaft-based surgical
forceps provided in accordance with the present disclosure is shown
generally identified by reference numeral 10. Although detailed
below with respect to forceps 10, the aspects and features of the
present disclosure are equally applicable for use with any suitable
shaft-based surgical instrument.
[0036] Forceps 10 is configured for grasping, treating, and/or
dissecting tissue and generally includes a housing 20, a handle
assembly 30, a trigger assembly 70, a shaft 80, an end effector
assembly 100, a drive assembly 140, a knife assembly 170, and an
energy activation assembly 190. As detailed below, shaft 80 extends
distally from housing 20 and supports end effector assembly 100 at
the distal end thereof; drive assembly 140 operably couples handle
assembly 30 with end effector assembly 100 to enable selective
manipulation of jaw members 110, 120 of end effector assembly 100
via actuation of movable handle 40 of handle assembly 30; knife
assembly 170 is operably coupled with trigger assembly 70 to enable
selective translation of a knife 174 of knife assembly 170 relative
to end effector assembly 100; and energy activation assembly 190
enables energy to be selectively delivered to end effector assembly
100.
[0037] Forceps 10 may also include an electrosurgical cable (not
shown) that connects forceps 10 to a generator (not shown) or other
suitable power source, although forceps 10 may alternatively be
configured as a battery-powered instrument. The electrosurgical
cable includes lead wires, e.g., lead wires 101, 102 (FIG. 6),
extending therethrough that have sufficient length to extend
through housing 20 and shaft 80 in order to operably couple the
generator, energy activation assembly 190, and end effector
assembly 100 with one another to enable the selective supply of
energy to jaw members 110, 120 of end effector assembly 100, e.g.,
upon activation of activation switch 194 of energy activation
assembly 190.
[0038] Continuing with reference to FIGS. 1-3, housing 20 of
forceps 10 houses the internal working components of forceps 10 and
defines a pistol-style configuration having a
longitudinally-extending barrel portion 24 and a fixed handle
portion 26 that extends from barrel portion 24 in generally
perpendicular orientation relative thereto. Activation switch 194
of energy activation assembly 190 is mounted on fixed handle
portion 26 of housing 20 such that activation switch 194 may be
activated by movable handle 40 upon sufficient movement of movable
handle 40 towards fixed handle portion 26 of housing 20, as
detailed below. Upon activation of activation switch 194, energy is
supplied from the generator (not shown) to jaw members 110, 120 of
end effector assembly 100 via lead wires 101, 102 (FIG. 6),
respectively.
[0039] Shaft 80 extends distally from housing 20 and defines a
generally rectangular cross-sectional configuration oriented such
that the larger width dimension thereof extends laterally and the
smaller height dimension thereof extends vertically. However, shaft
80 may alternatively define a square, polygonal, oval, or circular
cross-sectional configuration and/or may define a different
orientation. As described in greater detail below, shaft 80
includes a pair of spaced-apart clevis members 84 extending
distally from the top and bottom walls, e.g., the larger width
dimension walls, of shaft 80 at distal end 85 thereof, each of
which defines an aperture 86 for receiving a pivot pin 103 to
operably support end effector assembly 100 at distal end 85 of
shaft 80. Shaft 80 also includes, at proximal end 82 thereof, a
pair of engagement apertures 87 configured to receive engagement
features (not shown) extending inwardly from housing 20 to secure
proximal end 82 of shaft 80 within housing 20.
[0040] With additional reference to FIGS. 4-6, shaft 80 further
includes a pair channels 88 define within the interior surfaces of
the top and bottom walls, e.g., the larger width dimension walls,
of shaft 80. Channels 88 may be formed via embossed features 89
that are raised in relief from the exterior surfaces of the top and
bottom walls of shaft 80, thereby defining channels 88 on the
opposite, interior surfaces of the top and bottom walls. Embossed
features 89 may be formed via stamping or other suitable process
and are configured such that channels 88 each define an angled
portion 88a and a longitudinal portion 88b. Angled portions 88a of
channels 88 are at least partially open to the distal end 85 of
shaft 80 to enable slidable insertion of the ends of cam pin 105 of
end effector assembly 100 into angled portions 88a of channels 88.
Once the ends of cam pin 105 have been inserted into angled
portions 88a of channels 88, cam pin 105 may be translated along
angled portions 88a of channels 88 such that the ends thereof are
translated through angled portions 88a and into longitudinal
portions 88b of channels 88. Longitudinal portions 88b of channels
88 define lengths equal to or greater than the length of travel of
cam pin 105 during movement of jaw members 110, 120 between the
spaced-apart and approximated positions (FIGS. 4 and 5,
respectively). The assembly and operable coupling of end effector
assembly 100 with shaft 80 and drive assembly 140 via cam pin 105
is detailed below.
[0041] Referring again to FIGS. 1-3, handle assembly 30 includes a
movable handle 40 that is movable relative to fixed handle portion
26 of housing 20 between an initial position and an activated
position. Drive assembly 140 is operably coupled between movable
handle 40 and end effector assembly 100 such that movement of
movable handle 40 relative to fixed handle portion 26 of housing 20
between the initial position and the activated position imparts
movement of jaw members 110, 120 of end effector assembly 100
between a spaced-apart position (FIG. 4) and an approximated
position (FIG. 5) for grasping tissue therebetween. Further, in the
activated position of movable handle 40, movable handle 40 is urged
into contact with activation switch 194 of energy activation
assembly 190 to activate activation switch 194 and thereby initiate
the supply of energy from the generator (not shown) to end effector
assembly 100 for treating grasped tissue.
[0042] Drive assembly 140 includes a drive plate 142 and a slider
assembly 150. Drive plate 142 extends distally from housing 20 and
through shaft 80 to operably engage end effector assembly 100. More
specifically, a cam-pin aperture 147 configured to receive cam pin
105 of end effector assembly 100 is defined transversely through
drive plate 142 towards the distal end of drive plate 142. Slider
assembly 150 operably couples movable handle 40 with drive plate
142. As a result of this configuration, movement of movable handle
40 between the initial position and the activated position
translates drive plate 142 through shaft 80 and, thus, translates
cam pin 105 relative to end effector assembly 100 to pivot jaw
members 110, 120 of end effector assembly 100 between the
spaced-apart and approximated positions (FIGS. 4 and 5,
respectively). A more detailed description of slider assembly 150
and other suitable slider assemblies configured for use with drive
plate 142 can be found in U.S. patent application Ser. Nos.
14/719,422; 14/719,434; 14/719,452; 14/719,464; and Ser. No.
14/719,475, each of which was filed on May 22, 2105 and is
incorporated by reference herein in its entirety.
[0043] Knife assembly 170 includes a knife 174 that is coupled to
trigger assembly 70 such that actuation of trigger 72 of trigger
assembly 70 advances knife 174 between jaw members 110, 120 of end
effector assembly 100 to cut tissue grasped therebetween. A more
detailed description of knife assembly 170 and trigger assembly 70
can be found in U.S. patent application Ser. Nos. 14/719,422;
14/719,434; 14/719,452; 14/719,464; and Ser. No. 14/719,475,
previously incorporated by reference herein.
[0044] With reference to FIGS. 3-6, as mentioned above, end
effector assembly 100 is operably supported at distal end 85 of
shaft 80 and includes opposing jaw members 110, 120 pivotably
coupled to one another and movable relative to one another shaft 80
between a spaced-apart position (FIG. 4) and an approximated
position (FIG. 5) for grasping tissue therebetween. Each jaw member
110, 120 includes an electrically-conductive plate 112, 122, a jaw
frame 113, 123, a spacer (not shown), and an outer housing 118,
128. Jaw members 110, 120 define curved configurations, wherein jaw
members 110, 120 bend upwardly from a longitudinal axis of shaft
80, e.g., towards the upper, larger width dimension wall of shaft
80, although linear jaw members or jaw members curved in a
different direction may alternatively be provided.
[0045] Jaw frames 113, 123 of jaw members 110, 120 each include a
pair of spaced-apart proximal flanges 114, 124 and a distal jaw
support (not shown). The distal jaw supports of jaw frames 113, 123
support electrically-conductive plates 112, 122, the spacers (not
shown), and outer housings 118, 128 of the respective jaw members
110, 120 thereon. Electrically-conductive plates 112, 122 are
electrically connected to energy activation assembly 190 (FIGS. 1
and 2) via leads 101, 102, respectively, and are
electrically-isolated from jaw frames 113, 123 via outer housings
118, 128 and/or the spacers (not shown).
[0046] Continuing with reference to FIGS. 3-6, proximal flanges 114
of jaw member 110 are spaced-apart further than proximal flanges
124 of jaw member 120 so as to allow proximal flanges 124 of jaw
member 120 to be positioned between proximal flanges 114 of jaw
member 110 during assembly, although proximal flanges 114, 124 of
jaw members 110, 120, respectively, may alternatively be configured
for positioning in an offset, overlapping configuration relative to
one another. Each pair of proximal flanges 114, 124 defines an
aligned pivot aperture 114a, 124a and an aligned cam slot 114b,
124b. Pivot pin 103 of end effector assembly 100 is configured for
insertion through apertures 86 of clevis members 84 of shaft 80 and
pivot apertures 114a, 124a to pivotably couple jaw members 110, 120
to shaft 80 and one another to enable jaw members 110, 120 to pivot
laterally, e.g., along the larger width dimension of shaft 80,
between the spaced-apart and approximated positions (FIGS. 4 and 5,
respectively). Pivot pin 103 and/or proximal flanges 114, 124 of
jaw members 110, 120 may include features (not shown) or otherwise
be configured to retain pivot pin 103 in engagement within pivot
apertures 114a, 124a of proximal flanges 114, 124 of jaw members
110, 120, e.g., to inhibit pivot pin 103 from transversely sliding
out of engagement with proximal flanges 114, 124, as detailed
below.
[0047] Cam slots 114b of proximal flanges 114 of jaw member 110 are
oppositely angled relative to cam slots 124b of proximal flanges
124 of jaw member 120. Cam pin 105 of end effector assembly 100 is
configured for insertion through cam slots 114b, 124b of proximal
flanges 114, 124 of jaw members 110, 120, as well as cam-pin
aperture 147 of drive plate 142 to operable couple drive plate 142
with jaw members 110, 120. As a result of this configuration, and
with cam slots 114b of proximal flanges 114 oppositely angled
relative to cam slots 124b of proximal flanges 124, translation of
drive plate 142 relative to jaw members 110, 120 translates cam pin
105 through cam slots 114b, 124b to pivot jaw members 110, 120
about pivot pin 103 and relative to one another and shaft 80
between the spaced-apart and approximated positions (FIGS. 4 and 5,
respectively).
[0048] The free ends of cam pin 105, which extend outwardly from
proximal flanges 114 of jaw members 110, 120 when inserted through
jaw members 110, 120 and drive plate 142, are configured for
receipt within longitudinal sections 88b of channels 88 of shaft
80, as noted above. Longitudinal sections 88b of channels 88 of
shaft 80 inhibit cam pin 105 from transversely sliding out of
engagement with cam slots 114b, 124b of proximal flanges 114, 124
of jaw members 110, 120 and cam-pin aperture 147 of drive plate
142. Longitudinal sections 88b of channels 88 also guide the
longitudinal translation of cam pin 105 relative to shaft 80 during
longitudinal translation of drive plate 142 through shaft 80 to
pivot jaw members 110, 120 between the spaced-apart and
approximated positions (FIGS. 4 and 5, respectively).
[0049] Referring generally to FIGS. 1-6, the assembly of end
effector assembly 100 and the coupling of the assembled end
effector assembly 100 with shaft 80 and drive plate 142 are
described. Initially, to assembly end effector assembly 100, jaw
members 110, 120 are manipulated such that proximal flanges 124 of
jaw member 120 are disposed between proximal flanges 114 of jaw
member 110 with the pairs of pivot apertures 114a, 124a of proximal
flanges 114, 124 of jaw members 110, 120, respectively, aligned
with each other. Once this position has been achieved, pivot pin
103 is inserted through the pivot aperture 114a of one of the
proximal flanges 114 of jaw member 110, the pivot apertures 124a of
the proximal flanges 124 of jaw member 120, and the pivot aperture
114a of the other proximal flange 114 of jaw member 110 such that
the ends of pivot pin 103 extend outwardly from each of the
proximal flanges 114 of jaw member 110.
[0050] As noted above, pivot pin 103 and/or proximal flanges 114,
124 of jaw members 110, 120 may include features (not shown) or
otherwise be configured to retain pivot pin 103 within pivot
apertures 114a, 124a. More specifically, once pivot pin 103 is
inserted through pivot apertures 114a, 124a as detailed above,
pivot pin 103 may be welded to the portions of the outwardly-facing
surfaces of proximal flanges 114 surrounding pivot apertures 114a
of jaw member 110, or may otherwise be engaged therewith to the
inhibit transverse sliding of pivot pin 103 relative to jaw member
110. Regardless of the configuration, in this assembled state end
effector assembly 100, pivot pin 103 is operably retained in
position with the ends of pivot pin 103 extending outwardly from
each proximal flange 114 of jaw member 110.
[0051] Once end effector assembly 100 has been assembled, e.g., as
detailed above, end effector assembly 100 may be coupled with shaft
80 and drive plate 142. That is, jaw members 110, 120 may initially
be coupled to one another to form end effector assembly 100,
followed by the assembled end effector assembly 100 being coupled
with shaft 80 and drive plate 142. In order to couple the assembled
end effector assembly 100 with shaft 80 and drive plate 142, cam
pin 105 is inserted through the cam slot 114b of one of the
proximal flanges 114 of jaw member 110, the cam slot 124b of one of
the proximal flanges 124 of jaw member 120, cam-pin aperture 147 of
drive plate 142, the cam slot 124b of the other proximal flange 124
of jaw member 120, and the cam slot 114b of the other proximal
flange 114 of jaw member 110 such that the ends of cam pin 105
extend outwardly from each of the proximal flanges 114 of jaw
member 110.
[0052] With cam pin 105 inserted through proximal flanges 114 of
jaw member 110, proximal flanges 124 of jaw member 120, and drive
plate 142, as detailed above, drive plate 142 is operably coupled
to cam pin 105 such that translation of drive plate 142 through
shaft 80 and relative to end effector assembly 100 translates cam
pin 105 through cam slots 114b, 124b of jaw members 110, 120,
respectively.
[0053] Once insertion of cam pin 105, as detailed above, has been
accomplished, end effector assembly 100 may be coupled to distal
end 85 of shaft 80. In order to couple end effector assembly 100 to
distal end 85 of shaft 80, the ends of cam pin 105 which extend
outwardly from jaw members 110, 120 are guided into the open distal
ends of angled portions 88a of channels 88 at the distal end 85 of
shaft 80 and are slid proximally along angled portions 88a of
channels 88 into longitudinal portions 88b of channels 88.
[0054] With the ends of cam pin 105 positioned within longitudinal
portions 88b of channels 88, cam pin 105 is retained in position
extending through proximal flanges 114 of jaw member 110, proximal
flanges 124 of jaw member 120, and drive plate 142 and is
restricted to longitudinal movement relative to shaft 80, despite
being "floating," that is, without otherwise being engaged with
shaft 80, jaw members 110, 120, or drive plate 142 other than the
fact that cam pin 105 extends through cam slots 114b, 124b, cam-pin
aperture 147, and has its ends disposed within channels 88. Upon
coupling of drive plate 142 with slider assembly 150, the
distal-most position of drive plate 142 relative to shaft 80, e.g.,
corresponding to the initial position of movable handle 40, is
defined such that cam pin 105 is inhibited from sliding distally
into angled sections 88a of channels 88 and, thus, is retained
within longitudinal sections 88a of channels 88. As noted above,
longitudinal sections 88a of channels 88 define lengths equal to or
greater than the length of travel of cam pin 105 during movement of
jaw members 110, 120 between the spaced-apart and approximated
positions (FIGS. 4 and 5, respectively) such that cam pin 105 need
only travel within longitudinal sections 88a of channels 88 and
such that longitudinal sections 88a of channels 88 permit full
pivoting of jaw members 110, 120 between the spaced-apart and
approximated positions (FIGS. 4 and 5, respectively).
[0055] During or after sliding the ends of cam pin 105 into
channels 88 to operably retain cam pin 105 therebetween, the ends
of pivot pin 103 are inserted into apertures 86 of spaced-apart
clevis members 84 to pivotably couple jaw members 110, 120 with
shaft 80 and to retain jaw members 110, 120 at distal end 85 of
shaft 80. This may be accomplished by flexing clevis members 84
apart from one another to permit the ends of pivot pin 103 to slide
along the inner surfaces of clevis members 84 and into alignment
with apertures 86. Upon achieving this alignment, clevis members 84
are released or return back to their original position such that
the ends of pivot pin 103 are urged through apertures 86 to
pivotably retain pivot pin 103 between clevis members 84.
[0056] As an alternatively to retaining pivot pin 103 in engagement
with jaw members 110, 120 and subsequently coupling the ends of
pivot pin 103 to clevis members 84, as detailed above, the
insertion of pivot pin 103 may be withheld until the end of the
above-detailed assembly. That is, in such embodiments, jaw members
110, 120 and drive plate 142 may be coupled to one another and
shaft 80 via the insertion of cam pin 105 through proximal flanges
114, 124 and drive plate 142 and sliding insertion of the ends of
cam pin 105 into channels 88 of shaft 80, similarly as detailed
above. Thereafter, with the pairs of pivot apertures 114a, 124a of
proximal flanges 114, 124 of jaw members 110, 120, respectively,
aligned with each other and apertures 86 of clevis members 84,
pivot pin 103 may be inserted through pivot apertures 114a, 124a
and apertures 86. Pivot pin 103 may be operably retained in
position once inserted in this manner via any suitable feature or
in any other suitable fashion, e.g., via welding the ends of pivot
pin 103 to clevis members 84, rivets formed on the ends of pivot
pin 103 that extend outwardly from clevis members 84, etc.
[0057] At any suitable point during the above-detailed assembly,
lead wires 101, 102 (FIG. 6) may be routed from jaw members 110,
120 through shaft 80 and into housing 20, ultimately to be
electrically coupled to energy activation assembly 190 and/or the
electrosurgical cable (not shown) to enable connection to the
generator (not shown).
[0058] Referring still to FIGS. 1-6, the use and operation of
forceps 10 is described. Initially, movable handle 40 is disposed
in the initial position, drive plate 142 is disposed in a
distal-most position to maintain cam pin 105 at the distal ends of
cam slots 114b, 124b and at the distal end of longitudinal sections
88b of channels 88 of shaft 80, and, correspondingly, jaw members
110, 120 are disposed in the spaced-apart position (FIG. 4).
Trigger 72 is initially is disposed in the un-actuated position
and, accordingly, knife 174 is disposed in a retracted position,
wherein knife 174 is disposed between proximal flanges 114, 124 of
jaw members 110, 120 but does not extend distally therefrom so as
to avoid interference with tissue disposed between jaw members 110,
120.
[0059] In order to move jaw members 110, 120 to the approximated
position to grasp tissue therebetween, movable handle 40 is pulled
proximally towards fixed handle portion 26 from the initial
position towards the activation position. Upon such movement of
movable handle 40, slider assembly 150 is translated proximally
through housing 20, thereby pulling drive plate 142 proximally. As
drive plate 142 is pulled proximally, cam pin 105 is pulled
proximally through cam slots 114b, 124b of jaw members 110, 120 and
longitudinal sections 88b of channels 88 of shaft 80 such that jaw
members 110, 120 are pivoted from the spaced-apart position (FIG.
4) towards the approximated position (FIG. 5) to grasp tissue
therebetween. As noted above, longitudinal section 88b of channels
88 of shaft 80 guide translation of cam pin 105 as cam pin 105 is
pulled through cam slots 114b, 124b and ensure that cam pin 105 is
translated longitudinally. This configuration reduces the
tolerances on cam pin 105 and, thus, enables use of a cam pin 105
having a relatively shorter length as compared to a cam pin that
does not have its ends seated within channels 88. As can be
appreciated, a shorter cam pin 105 allows for a smaller-diameter
shaft, which is advantageous for use in endoscopic procedures and
in other procedures with significant spatial constraints.
[0060] In order to apply energy to tissue grasped between jaw
members 110, 120 to treat tissue, movable handle 40 is moved
further towards fixed handle portion 26 to the activation position,
wherein an appropriate closure force or closure force within an
appropriate range, is achieved, as described in detail in U.S.
patent application Ser. Nos. 14/719,422; 14/719,434; 14/719,452;
14/719,464; and Ser. No. 14/719,475, previously incorporated by
reference herein. Further, in the activation position of movable
handle 40, energy activation is initiated. More specifically, in
the activation position, movable handle 40 contacts switch 194
sufficiently so as to depress and activate switch 194. Switch 194,
as noted above, is disposed in electrical communication with the
generator (not shown) and electrically-conductive plates 112, 122
of jaw members 110, 120, respectively, such that activation of
switch 194 initiates the supply of energy to
electrically-conductive plates 112, 122 to treat, e.g., coagulate,
cauterize, and/or seal, tissue grasped therebetween.
[0061] Once tissue has been treated or where it is only desired to
cut tissue, knife 174 may be advanced between jaw members 110, 120
to cut tissue grasped therebetween. In order to advance knife 174
from the retracted position to an extended position, trigger 72 is
pulled proximally from an un-actuated position to an actuated
position. As trigger 72 is pulled proximally, trigger assembly 70
cooperates with knife assembly 170, as detailed in U.S. patent
application Ser. Nos. 14/719,422; 14/719,434; 14/719,452;
14/719,464; and Ser. No. 14/719,475, previously incorporated by
reference herein, to advance knife 174 distally. As knife 174 is
advanced distally, knife 174 enters knife slots 117 (only the knife
slot of jaw member 110 is shown) defined within
electrically-conductive plates 112, 122 of jaw members 110, 120,
respectively, and translates therethrough to the extended position
to divide tissue grasped between jaw members 110, 120.
[0062] The various embodiments disclosed herein may also be
configured to work with robotic surgical systems and what is
commonly referred to as "Telesurgery." Such systems employ various
robotic elements to assist the surgeon and allow remote operation
(or partial remote operation) of surgical instrumentation. Various
robotic arms, gears, cams, pulleys, electric and mechanical motors,
etc. may be employed for this purpose and may be designed with a
robotic surgical system to assist the surgeon during the course of
an operation or treatment. Such robotic systems may include
remotely steerable systems, automatically flexible surgical
systems, remotely flexible surgical systems, remotely articulating
surgical systems, wireless surgical systems, modular or selectively
configurable remotely operated surgical systems, etc.
[0063] The robotic surgical systems may be employed with one or
more consoles that are next to the operating theater or located in
a remote location. In this instance, one team of surgeons or nurses
may prep the patient for surgery and configure the robotic surgical
system with one or more of the instruments disclosed herein while
another surgeon (or group of surgeons) remotely control the
instruments via the robotic surgical system. As can be appreciated,
a highly skilled surgeon may perform multiple operations in
multiple locations without leaving his/her remote console which can
be both economically advantageous and a benefit to the patient or a
series of patients.
[0064] The robotic arms of the surgical system are typically
coupled to a pair of master handles by a controller. The handles
can be moved by the surgeon to produce a corresponding movement of
the working ends of any type of surgical instrument (e.g., end
effectors, graspers, knifes, scissors, etc.) which may complement
the use of one or more of the embodiments described herein. The
movement of the master handles may be scaled so that the working
ends have a corresponding movement that is different, smaller or
larger, than the movement performed by the operating hands of the
surgeon. The scale factor or gearing ratio may be adjustable so
that the operator can control the resolution of the working ends of
the surgical instrument(s).
[0065] The master handles may include various sensors to provide
feedback to the surgeon relating to various tissue parameters or
conditions, e.g., tissue resistance due to manipulation, cutting or
otherwise treating, pressure by the instrument onto the tissue,
tissue temperature, tissue impedance, etc. As can be appreciated,
such sensors provide the surgeon with enhanced tactile feedback
simulating actual operating conditions. The master handles may also
include a variety of different actuators for delicate tissue
manipulation or treatment further enhancing the surgeon's ability
to mimic actual operating conditions.
[0066] From the foregoing and with reference to the various figure
drawings, those skilled in the art will appreciate that certain
modifications can also be made to the present disclosure without
departing from the scope of the same. While several embodiments of
the disclosure have been shown in the drawings, it is not intended
that the disclosure be limited thereto, as it is intended that the
disclosure be as broad in scope as the art will allow and that the
specification be read likewise. Therefore, the above description
should not be construed as limiting, but merely as exemplifications
of particular embodiments. Those skilled in the art will envision
other modifications within the scope and spirit of the claims
appended hereto.
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